Wheel With Flexible Wide-Body Spokes

ABSTRACT

A wheel with flexible spokes, including a rim and hub, and spokes between the rim and hub made of fibrous material that causes the spokes to be both lighter in weight and stronger than comparable steel spokes. The spokes are also flexible and resilient such that they can bend while retaining their integrity and strength.

RELATED APPLICATION

This application is a continuation-in-part application of U.S. Utilityapplication Ser. No. 16/195,648 filed Nov. 19, 2018, entitled “Wheelwith Flexible Wide-Body Spokes,” which is a continuation of U.S. Utilityapplication Ser. No. 15/451,766 filed Mar. 7, 2017, entitled “Wheel withFlexible Wide-Body Spokes,” issued as U.S. Pat. No. 10,131,181, which isa continuation of U.S. Utility application Ser. No. 14/667,477 filedMar. 24, 2015, entitled “Wheel with Flexible Wide-Body Spokes,” issuedas U.S. Pat. No. 9,636,943, which is a continuation-in-part Applicationto U.S. Utility application Ser. No. 13/487,253 filed Jun. 4, 2012,entitled “Wheel With Flexible Wide-Body Spokes,” issued as U.S. Pat. No.8,985,707.

FIELD OF INVENTION

The present invention is directed to vehicular wheels havinghigh-strength and light-weight spokes, particularly bicycle, motorcycle,and wheelchair wheels.

BACKGROUND OF INVENTION

The most common construction for bicycle wheels includes spokes made ofstainless steel or other metal. While stainless steel is strong, it isalso heavy. Therefore, the spokes must be made as thin as possible tomake them as light as possible. However, the thinner the spoke, the lessstrength it has. The thicker the spoke, the stronger it is. Therefore,in making spokes of steel, there is a tradeoff between making the spokesstrong and making them lightweight. Thus, there is a need for a wheelwith spokes that can be both lightweight and strong without having todeal with this tradeoff between the two. Another problem with steelspokes is that, if they are bent, they weaken and ultimately fail suchthat they must be replaced if bent.

One solution to this problem was presented in U.S. Pat. No. 5,110,190which issued to Harold Johnson on May 5, 1992, for an invention entitled“High Modulus Multifilament Spokes And Method” (hereinafter the “'190patent”). The '190 patent is fully incorporated herein by thisreference. The '190 patent discloses a high modulus multifilamentnon-rigid and rigid wheel spoke that includes a fiber mid-portionbetween a first and second end having attachment members affixedthereto. The '190 patent also discloses methods of supporting a hubwithin a wheel rim by means of a plurality of spokes or by means ofcontinuous lengths of spokes.

While the device presented in the '190 patent clearly made advancementsover the state of the art at that time, the device nevertheless has itsshortcomings. For instance, the small diameter of the filament spokesrequires that the spokes be maintained in a substantially axialarrangement with its connectors. This, unfortunately, makes themanufacturing of wheels incorporating the '190 technology more difficultdue to the of off-axis tension. Specifically, even though the spokes ofthe '190 patent are orders of magnitude stronger than their metalliccounterparts, the strength of the '190 spokes is slightly decreased fromits maximum strength due to the bend in the spokes as they leave thewheel rim when installed in a wheel.

U.S. Pat. No. 6,036,281 which issued on Mar. 14, 2000, to RichardCampbell and entitled “Low Rotational Mass Bicycle Wheel System”(hereinafter the '281 patent), disclosed a bicycle wheel system havingspokes extending radially from hub to spoke. The spokes are providedwith fittings at its rim end which are constructed with minimal mass andfittings at the hub end which allow adjustment of the tension of thespoke. The spokes are constructed of a bundle of liquid crystal fibershaving no significant creep surrounded by an extruded plastic jacket.

While the spoke presented in the '281 patent certainly represents amilestone in bicycle wheel technology and light-weight wheelmanufacturing, it nevertheless has its challenges with implementation.First of all, there are manufacturing challenges in keeping the spokesaligned with their connectors. In narrow-width wheel applications, thedevice disclosed in the '281 are difficult to install as the alignmentis important. This alignment results in increased assembly costs andoverall product costs.

The present invention resolves these problems by providing spokes thatare both lighter in weight than steel and significantly stronger thansteel, and that are flexible such that they can bend without sufferingdamage. Moreover, due to their significant strength and durability,fewer numbers of spokes are required on wheels while still providing alightweight wheel with superior strength. Further, the addition ofaerodynamic jackets over the spoke work to reduce drag as the spokerotates during use.

SUMMARY OF THE INVENTION

The wheel with flexible wide-body spokes of the present inventionprovides the aforementioned advantages by providing a wheel including arim and hub, and spokes between the rim and hub made of fibrous materialthat causes the spokes to be both lighter in weight and stronger thancomparable steel spokes. The spokes are also flexible and resilient suchthat they can bend while retaining their integrity and strength.Further, an aerodynamic cover is formed over the fibrous material

BRIEF DESCRIPTION OF DRAWINGS

The aforementioned and other advantages of the wheel with flexiblespokes of the present invention will become more apparent to thoseskilled in the art upon making a thorough review and study of thefollowing detailed description of the invention when reviewed inconjunction with the drawings in which like references numerals refer tolike parts, and wherein:

FIG. 1 is a side view of a first preferred embodiment of the wheel withflexible spokes of the present invention, showing the rim, hub, spokesbetween rim and hub, tubes attaching each spoke to the rim, and anchorsattaching each spoke to the hub;

FIG. 2 is a rear detail view of the first preferred embodiment of thewheel with flexible spokes of the present invention, showing the hub,the angle between spokes on the left side of the wheel and spokes on theright side of the wheel, and the angle of the hub surface at the pointof attachment of each spoke to the hub;

FIG. 3 is a cross-sectional view of the first preferred embodiment ofthe wheel with flexible spokes of the present invention, taken acrossline 3-3 of FIG. 1, showing cross-sectional portions of the rim and hub,and showing how each tube attaches each spoke to the rim via a nipple inthe rim, and how each anchor attaches each spoke to the hub;

FIG. 4 is a cross-sectional view of the first preferred embodiment ofthe wheel with flexible spokes of the present invention, taken acrossline 4-4 of FIG. 1, showing a cross-sectional view of the fibers andjacket of one of the spokes;

FIG. 5 is a cross-sectional view of the first preferred embodiment ofthe wheel with flexible spokes of the present invention showingcross-sectional portions of the rim and hub, and showing how each tube,once attached to the rim, would extend away at an angle from the nipplein the rim;

FIG. 6 is a side view of an alternative embodiment of the wheel withflexible spokes of the present invention showing a flexible spoke formedwith a jacket having an aerodynamic tear-drop shape;

FIG. 7 is a cross-sectional view of a flexible spoke of the presentinvention as taken through line 7-7 of FIG. 6 having a jacket over thecentral fibers formed in an aero-dynamic teardrop shape;

FIG. 8 is a cross-sectional view of a flexible spoke of the presentinvention having a jacket formed over the central fibers in anaero-dynamic oblong shape;

FIG. 9 is a cross-sectional view of a flexible spoke of the presentinvention having a jacket formed over the central fibers in anaero-dynamic shape having a pointed leading and trailing edge;

FIG. 10 is a perspective view of a mold used to form the jacket in adesired shape around the central fiber bundle;

FIG. 11 is a perspective view of an alternative heated mold used to forma jacket having two different cross-sections;

FIG. 12 is a perspective view of the alternative heated mold in FIG. 11closed around a spoke blank;

FIG. 13 is a perspective view of the alternative heated mold afterseparating the pieces of the mold to show a spoke having two differentcross-sections; and

FIG. 14 is a side view of an alternative embodiment of the wheel withflexible spokes of the present invention showing a flexible spoke formedwith a jacket having two different cross-sections, an aerodynamictear-drop shape and a circular shape.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a side view of a first preferred embodiment of thewheel with flexible spokes of the present invention is shown andgenerally designated 100. In FIG. 1, the side of wheel 100 facing theviewer can be referred to as the right side of the wheel 100. The sideof wheel 100 opposite the right side can be referred to as the left sideof the wheel 100. The wheel 100 has a wheel axis 104, and a rim 110which has an inner perimeter 112 and an outer perimeter 114. Direction102 is the preferred direction of rotation of wheel 100 however it is tobe appreciated that wheel 100 is free to rotate in the directionopposite direction 102.

Still referring to FIG. 1, with reference to FIG. 2 and FIG. 3,distributed symmetrically along inner perimeter 112 are spoke holes 120.Each spoke hole 120 has a spoke hole width 122. Along the outerperimeter 114 are nipple access holes 124 (not visible in FIG. 1, seeFIG. 3), one nipple access hole 124 adjacent each spoke hole 120. Wheel100 further includes a hub 130 having a right flange 132 and a leftflange 134 (not visible, behind right flange 132). Each flange 132 and134 has an inner surface 136 and an outer surface 138. In each flange132 and 134 are flange holes 140, each flange hole 140 corresponding toa unique spoke hole 120. Each flange hole 140 has an inner opening 142in the corresponding inner surface 136, and an outer opening 144 in thecorresponding outer surface 138. Hub 130 also has a barrel 148 whichreceives an axle of a bicycle.

Wheel 100 further includes non-rigid spoke members, or spokes 150. Eachspoke 150 has non-rigid fibers 152 (not visible this Figure) covered bya jacket 154 having an inner diameter 156 (not visible) and an outerdiameter 158 which is also the width 158 of spoke 150. Each spoke 150has a length 160. Fibers 152 are substantially continuous along thelength 160 of spoke 150. Alternatively, one or more of fibers 152 may beless than continuous along the length of spoke 150.

Each spoke 150 has an inner end 162 adjacent hub 130, and an outer end164 adjacent rim 110. Each spoke 150 has a tube 170 about its outer end164, and each tube 170 is formed with a tapered bore 171 opening awayfrom the tube axis 172 of the spoke 150. Each tube 170 is affixed to itscorresponding outer end 164 by inserting the fibers 152 into the tube170, and filling the tube 170 with epoxy 163. Once hardened, the epoxy163 and fibers 152 form a wedge within the tapered bore 171 such thatany tension on the spoke 150 draws the hardened wedge against the taperthereby securing the fiber within the tube 170. Alternatively, tube 170may be affixed to outer end 164 by any other material of similarstrength.

Tube 170 may be equipped with a hexagonal, reinforced head 165 whichprovides for added strength at the rim-end 164 of the tube 170. This ishelpful in preventing breakage from non-axial tension on spoke 150, andfacilitates the tightening of spoke 150.

Each tube 170 has a tube axis 172 and external spoke threads 174. Eachspoke 150 also has an anchor (or eyelet or ferrule) 180 about its innerend 162. Each anchor 180 is formed with a tapered bore 181 opening awayfrom the tube axis 172. Each anchor 180 is affixed to its correspondinginner end 162 by inserting the fibers 152 into the anchor 180, andfilling the tapered bore 181 with epoxy 163. Once hardened, the epoxy163 and fibers 152 form a wedge within the tapered bore 181 formed inthe anchor 180 such that any tension on the spoke 150 draws the hardenedwedge against the tapered bore 181 thereby securing the fiber 150 withinthe anchor 180. Alternatively, anchor 180 may be affixed to inner end162 by any other material of similar strength.

Each flange hole 140 is wider than spoke 150 but narrower than anchor180, such that tube 170 about outer end 164 can be passed into inneropening 142 and out of outer opening 144, and such that the rest ofspoke 150 can then be passed through flange hole 140 until anchor 180comes into contact with inner surface 136 around inner opening 142,which causes inner end 162 to be retained in flange hole 140 by anchor180.

Wheel 100 also includes nipples 190. One nipple 190 is shown in FIG. 1in broken line, inside rim 110. There is a nipple 190 between each spokehole 120 and its corresponding nipple access hole 124. Each nipple 190has a nipple opening 192, nipple threads 194 inside nipple opening 192,a collar 196, and a nipple head 198. Once each spoke 150 is passedthrough flange hole 140 until anchor 180 comes into contact with innersurface 136 around inner opening 142, tube 170 is positioned andthreaded into the corresponding nipple 190 via inter-engagement of spokethreads 174 with nipple threads 194. This causes tube 170 to be retainedin nipple 190 such that tube axis 172 is perpendicular to wheel axis 104(shown in FIG. 1). The retention of tube 170 in nipple 190 and of innerend 162 in flange hole 140 by anchor 180 causes spoke 150 to be heldtaut between rim 110 and hub 130.

FIG. 1 shows eight (8) spokes 150 attached to right flange 132, andeight (8) spokes 150 attached to left flange 134 (not visible, behindright flange 132), for a total of sixteen (16) spokes 150. Wheel 100 mayalternatively have more or fewer than sixteen (16) spokes 150. Forexample, wheel 100 may have twelve (12) spokes 150, six (6) spokes 150attached to each of flanges 132 and 134. While it is also possible tohave different numbers of spokes 150 attached to each of flanges 132 and134, having the same number of spokes attached to each of flanges 132and 134 balances the load on the flanges 132 and 134.

FIG. 2 is a rear view of hub 130. FIG. 2 shows the angle 250 that one ofthe spokes 150 is attached to right flange 132, and the correspondingangle 250 that one of the spokes 150 is attached to left flange 134. InFIG. 2, the right side of wheel 100 is on the right side of FIG. 2, andthe left side of wheel 100 is on the left side of FIG. 2. Broken line230 in FIG. 2 represents a plane 230 that bisects wheel 100 between theright side and left side of wheel 100. Plane 230 is perpendicular towheel axis 104. Each outer surface 138 has the shape of a conicalsection that has an angle 240 to wheel axis 104. Each spoke 150 extendsperpendicularly from the corresponding outer surface 138. Therefore,each spoke 150 extends from outer surface 138 at an angle 250 to plane230. This means that the magnitude of angle 260 between spoke 150attached to right flange 132 and spoke 150 attached to left flange 134,is twice the magnitude of angle 250.

FIG. 3 shows a partial cross-sectional detail view of a spoke 150 withits inner end 162 retained in flange hole 140 by anchor 180, and tube170 about to be received in nipple 190 in rim 110. FIG. 3 shows hownipple 190 is retained in spoke hole 120. Spoke hole width 122 allowsthe portion of nipple 190 around nipple opening 192 to pass throughspoke hole 120, but does not allow collar 196 to pass through spoke hole120, such that nipple is retained in spoke hole 120 by the tension ofspoke 150 on nipple 190 once tube 170 is threaded into nipple 190. FIG.3 also shows spoke threads 174 which inter-engage with nipple threads194 in thread tube 170 into nipple 190. With tube 170 retained in nipple190, tube axis 172 is perpendicular to wheel axis 104 (not shown, seeFIG. 2) and intersects the corresponding spoke hole 120. Spoke holes 120lie in plane 230. While spoke holes 120 may alternatively be adjacentplane 230, spoke holes 120 being in plane 230 causes the forces ofspokes 150 to be placed on rim 110 where plane 230 intersects rim 110,which is the middle of the inner perimeter 112 of rim 110. With spokeholes 120 in plane 230, and each tube 170 received in the correspondingnipple 190, tube axis 172 also lies in plane 230 (as shown in FIG. 5).

Referring now to FIG. 5, when each tube 170 is received in thecorresponding nipple 190, tube axis 172 also lies in plane 230 and tubeaxis 172 coincides with the broken line representing plane 230. However,because each spoke 150 extends at angle 250 to plane 230, each spoke 150extends from its tube 170 at angle 250 to tube axis 172. This means thatthere is a bend in spoke 150 at an angle 250 at the point 320 wherespoke 150 protrudes from tube 170. With steel spokes, such a bend wouldweaken the spoke and ultimately cause the spoke to fail. However, withspokes 150, such a bend does not damage spokes 150, because fibers 152are flexible and resilient yet strong such that spokes 150 retain theirintegrity and strength even when bent under tension in the mannerdescribed. Therefore, spokes 150 can bend without weakening or failing.Furthermore, each of spokes 150 is three times as strong, and weighshalf as much, as a steel spoke that would otherwise be used in itsplace. This allows the width 158 of each of spokes 150 to be greaterthan that of a steel spoke that would be used in its place. In thealternative, the width 158 of each spoke 150 may be less than or equalto the width of a steel spoke that would be used in its place; thestrength of each of spokes 150 may be greater or less than three timesthat of a steel spoke that would be used in its place; and the weight ofeach of spokes 150 may be greater or less than half that of a steelspoke that would be used in its place.

Rim 110, hub 130, tube 170, anchor 180 and nipple 190, in a preferredembodiment, are made of aluminum. Alternatively, any of rim 110, hub130, tube 170, anchor 180 or nipple 190 may be made of any othermaterial of comparable strength. In a preferred embodiment of thepresent invention, fibers 152 are a bundle of thermotropic liquidcrystal fibers that exhibit high strength, low creep, and weatherresistance. For instance, the fibers could be PBO fiber such as Zylon®,a strong yet lightweight fiber, available from Toyobo. Alternatively,fibers 152 may be made of any other material having comparable weightand strength. Jacket 154 is made of Rilsan®, a high performancepolyamide. Alternatively, jacket 154 may be made of any other materialhaving comparable weight and strength. Each nipple access hole 124allows access to nipple head 198 so that it can be turned to facilitatethe threading of nipple 190 onto tube 170. For instance, a hexagonalhead nut-driver may be positioned over nipple 190 and rotated to tightenspoke 150 in place.

FIG. 4 shows a cross-sectional detail view of the inside of a spoke 150,showing the fibers 152, outer diameter 158, and inner diameter 156 ofjacket 154. Fibers 152 are gathered in forty-four (44) bundles 410 ofnine-hundred ninety-six (996) fibers 152 in each bundle, for a total of43,824 fibers 152 in spoke 150. This great number of fibers 152 is onefactor contributing to the great strength of spoke 150, while minimizingthe weight of spoke 150. Spoke 150 has a breaking strength of 3,600pounds. Alternatively, the number of bundles 410 may be greater or lessthan 44; the number of filaments in each bundle 410 may be greater orless than 996; and the breaking strength of spoke 150 may be greater orless than 3,600 pounds.

Referring back to FIG. 5, the cross-sectional view of the firstpreferred embodiment of the wheel with flexible spokes of the presentinvention showing cross-sectional portions of the rim and hub is shown.As can be appreciated from FIG. 5, the width of rim 110 is just slightlywider than the width of nipple 190. As a result, it is necessary thatnipple 190 be aligned so that the spoke 150 extends radically inwardfrom rim 110. Because of this positioning, it is important that spoke150 be flexible as it leaves nipple 190 so as to accommodate angle 250without any decrease in strength and durability. Due to the number offibers 152 contained within spoke 150, there is no noticeable decreasein strength despite the off-axis tension.

When tension is applied to spoke 150, collar 196 strikes the insidesurface of rim 110 and maintains the nipple 190, and correspondingsleeve, in its perpendicular arrangement.

Referring to FIG. 6, an alternative embodiment of the flexible spoke isshown and generally designated 700. Spoke 700 consists of a tube 770having threads 774, an anchor 780, and a jacket 702. When mounted intorim 110, threads 774 engage with threads 194 (not shown, see FIG. 5) innipple 790. Tube 770 having threads 774, anchor 780, and nipple 790 aresubstantially similar to tube 170 having threads 174, anchor 180, andnipple 190 as described and fully detailed above in FIGS. 1-5,respectively. In this alternative embodiment, jacket 702 is formed inthe shape of a teardrop (see FIG. 7). As is known in the industry,teardrop shapes are efficient due to the reduced amount of drag producedby the flow of air over the shape. In this embodiment, jacket 702consists of a leading edge 714 and a trailing edge 716. When spoke 700in installed in wheel 100, spoke 700 is oriented such that leading edge714 points in direction 102, which is the direction of rotation of wheel100. It is to be appreciated that trailing edge 716 points in thedirection opposite direction 102.

In this embodiment, the teardrop shape creates less drag than a typicalround spoke due the reduced drag created by the teardrop shaped jacket702. Less drag is due to the reduced wake created when spoke 700 rotatesthrough air as compared to a typical round spoke. A typical round spokehas only 50% of the drag of a flat plate traveling at the same ratethrough the air. However, a properly dimensioned teardrop shape has 5%or less of the drag of a flat plate traveling at the same rate throughthe air. Even an improperly dimensioned teardrop shape has approximately5%-20% of the drag of a flat plate traveling at the same rate throughthe air.

During typical bicycle racing, riders can achieve speeds of 40 mph. Fora typical wheel, this means that the outer end of spoke 700 is alsotraveling at approximately 40 mph thereby creating increased drag asmeasured when moving away from the hub of the wheel. Assuming a racingbike wheel has a diameter of 22 inches, 40 mph roughly translates intothe rim portion of the wheel rotating at 704 inches per second, meaningthat the outer portion of a spoke is also moving through the air atapproximately 704 inches per second. In contrast, the portion of thespoke measured at 6 inches from the center of the wheel's hub istraveling at 333 inches per second. When racing, this increased dragcaused by round spokes moving at the above mentioned speeds reduces thebicycle's speed thereby requiring the expending of more energy tomaintain the desired speed of 40 mph. As the number of spokes isincreased, the amount of drag created by the spokes also increases.

To minimize the amount of drag created by the round spokes movingthrough the air, an aerodynamic jacket is applied to the spoke. In FIG.6, a teardrop jacket 702 is shown applied to a spoke 700. When jacket702 is properly applied to the spoke 700 such that leading edge 714travels in direction 102, spoke 700 will have greatly reduced drageffects, up to 95% less than round spokes without an aerodynamic cover.The reduced drag results in a reduced amount of energy required tomaintain any given speed. Alternatively, a higher speed may be achievedwhen applying the same amount of energy to a wheel having typical roundspokes. This reduced drag effect will be a substantial benefit to aperson racing on a bike with aerodynamic spokes as compared to a personracing without aerodynamic spokes since, in part, the difference between1^(st) place and 10^(th) place in a bicycle race can be one (1) secondor less. Over the course of a bicycle race, the reduced drag can resultin decreasing race times by several seconds.

Moving on to FIG. 7, a cross-section of the spoke 700 taken through line7-7 of FIG. 6 is shown. Fibers 152 are shown with a jacket in the shapeof a teardrop formed around fibers 152, having a leading edge 714 and atrailing edge 716. Fibers 152 are located in the leading half of thespoke 700 as defined by line 704. Fibers 152 are also located in thecenterline of spoke 700 as defined by line 706. It is to be appreciatedthat fibers 152 may be located at any point along line 706 fromintersection 708 to leading edge 714, with fibers 152 typically locatedaround the mid-point of the line between intersection 708 and leadingedge 714.

FIGS. 8 and 9 show alternative cross-sections of an aerodynamic spoke.FIG. 8 shows a cross section view of an aerodynamic spoke with an oblongshape jacket 702 a formed in an oblong shape. In this embodiment, thespoke must be oriented such that the leading edge 714 and trailing edge716 are in-line with direction 102. FIG. 9 is another alternativeembodiment of the present invention. FIG. 9 shows a cross section viewof an aerodynamic spoke with a pointed leading edge jacket 702 b formedwith a pointed leading edge 714 b and trailing edge 716 b. As with theembodiment in FIG. 8, aerodynamic spoke 730 must be oriented such thatleading edge 714 b and trailing edge 716 b are in-line with direction102. Similar to the tear drop shape discussed in relation to FIG. 7, theoblong shape and the pointed shape spokes will also work to reduce dragcreated by the spoke as it rotates in the air.

Now referring to FIG. 10, a mold for manufacturing the aerodynamic spokeof the present invention is shown and generally designated 800. Mold 800consists of upper block 802 and lower block 804. Upper block 802 has anupper channel 806 formed in the shape of the desired jacket, such as theteardrop shape of FIG. 7. Lower block 804 has a lower channel 808corresponding to upper channel 806. To manufacture an aerodynamic spokeof the present invention, Fibers 152 are gathered into the desirednumber of bundles and cut to the desired length to form bundle 410.Bundle 410 is then placed in lower channel 808 of lower block 804 suchthat the ends of bundle 410 extend beyond the edges of lower block 804.Upper block 802 is then secured to lower block 804 in direction 810 suchthat bundle 410 is located in the space formed between upper and lowerchannels 806 and 808. The desired material used to form the jacket isthen injected into the channel causing the material to form in the shapeof the space created by upper and lower channels 806 and 808. After thenewly formed aerodynamic spoke has solidified in mold 800, upper block802 and lower block 804 are separated thereby releasing the spoke fromthe mold 800.

Due to the shape and size of an aerodynamic spoke of the presentinvention 150 as compared to a traditional spoke, jacket 702 may notpass through flange hole 140 thereby preventing the assembly of thespoke into wheel 100. To overcome this limitation, anchor 180 may bedesigned such that inner end 162 is formed with a tube similar to tube170 having threads on the outside of the tube. To assemble wheel 100,the near end 162 of spoke with aerodynamic jacket 150 is insertedthrough flange hole 140 then secured with a nipple, similar to nipple190. Far end 164 is then inserted into nipple 190 and tightened untilthe desired tension is achieved.

Referring now to FIG. 11, a perspective view of an alternative heatedmold is shown and generally referred to as 900. Mold 900 consists ofupper block 902 having upper channel 906 and heater 910, lower block 904having lower channel 908 and heater 911 (shown in dashed lines), spokeblank 912 having a first end 914 and a second end 916 and covered in ajacket 918. As shown in FIG. 11, upper and lower channels 906 and 908transition from a first shape (Teardrop, See FIG. 7) to a second shape(Oblong, See FIG. 8). In practice, as will be discussed further below,heated mold 900 will result in a spoke where jacket 918 has a teardropcross-section (See FIG. 7) along one portion of the spoke, which thentransitions into an oblong cross-section along the remaining portion(See FIG. 8). It is to be appreciated by someone skilled in the art thatspoke 912 may be formed with three or more cross-sections along thelength of spoke 912 to create a specific drag profile along the lengthof spoke 912.

Now Referring to FIG. 12, heated mold 900 is shown in the closedposition by bringing upper block 902 and lower block 904 together withspoke blank 912 located between upper and lower block 902 and 904 inupper and lower channels 906 and 908. When mold 900 is in the closedposition, heaters 910 and 911 are energized to heat blank 912 such thatjacket 918 forms to the shape of upper and lower channels 906 and 908.After spoke 912 has formed to upper and lower channels 906 and 908,heaters 910 and 911 are de-energized to allow mold 900 and spoke blank912 to cool to ambient temperature.

In FIG. 13, after mold 900 and spoke blank 912 have cooled to ambienttemperature, upper block 902 and lower block 904 are separated allowingspoke 912 to be removed from mold 900. As can be seen in FIG. 13, spoke912 now has two distinct cross-sections. The first cross-section, astaken through line 7-7, at first end 914 is a tear-drop shape as seen inFIG. 7. Moving toward second end 916, spoke 912 transitions from thetear-drop shape of FIG. 7 to an oblong shape, as taken through line 8-8,as shown in FIG. 8. It is to be appreciated by someone skilled in theart that spoke 912 may be a combination of two or more shapes as neededto minimize wind resistance. For example, spoke 912 may have a teardropshape (See FIG. 7) at first end 914 and an aerodynamic shape havingpointed leading and trailing edges (See FIG. 9) at second end 916. As afurther example, spoke 912 may be formed with a teardrop shape thattransitions into an oblong shape that in turn transitions into a roundshape.

It is to be appreciated by someone skilled in the art that theaerodynamic spoke described in reference to FIGS. 11-13 may be createdby injecting the jacket material into mold 900, as described inconjunction with FIG. 10. To form a spoke, a fiber bundle is insertedinto the channel formed by upper and lower channels 906 and 908 whenupper block 902 is closed against lower block 904. Next, the jacketmaterial is injected into the formed channel containing the fiberbundle. In certain embodiments, mold 900 may require the use of one ofmore heaters to aid in the manufacturing process. In other embodiments,the injected jacket material may be injected when mold 900 is at ambienttemperature. After the spoke is formed, upper block 902 and lower block904 are separated and the aerodynamic spoke is removed from mold 900.

Referring now to FIG. 14, a side view of spoke 912 having two distinctcross-sections is shown. Spoke 912 includes non-rigid fibers 152 (shownin dashed lines) with a wedge 161 (shown in dashed lines) on each end.Attached to the non-rigid fibers 152 and jacket 918 are a first tube 920having a tapered bore 921 (shown in dashed lines) and threads 922 at thefirst end 914 and a second tube 930 having a tapered bore 931 (shown indashed lines) and threads 932 at the second end 916. The jacket 918having two distinct cross-sections covers the non-rigid fibers 152between the first tube 920 and the second tube 930. The spoke 912further includes a first nipple 924 having a bore configured to threadonto threads 922 and a second nipple 934 having a bore configured tothread onto threads 932. First tube 920, first nipple 924, second tube930, and second nipple 934 are substantially similar to tube 170 andnipple 190 as described and fully detailed above in FIGS. 1-5. Whenmounted into rim 110, threads 922 engage with the bore (not shown) innipple 924 and threads 932 engage with the bore (not shown) in nipple934. The spoke 912 has the ability to be adjusted at the first end 914or at the second end 916 by adjusting the corresponding nipple. Thetwo-distinct cross sections of jacket 918 of spoke 912 is not meant tobe limiting and it is contemplated that the jacket 918 of spoke 912 mayhave multiple distinct cross-sections. It is further contemplated thatspoke 912 may have a single distinct cross-section, wherein the jacket918 has a single distinct cross section similar to the jacket 702 shownin FIG. 6.

Moreover, it is contemplated that the non-rigid fibers 152 may also becovered by jacket 154 (shown in FIGS. 3-5) before being covered byjacket 918. By placing jacket 154 over the non-rigid fibers, a completedbase spoke is utilized as a base spoke for the application ofaerodynamic jacket 918. The base spoke further includes the first tube920 having threads 922 at the first end 914 and the second tube 930having threads 932 at the second end 916. The jacket 154 and jacket 918may be made of the same material and during the heating process willthermally mold and attach the jacket 918 and jacket 154. It iscontemplated that other attachment means may be utilized. The use ofdual tubes and nipples is not meant to be limited to only aerodynamicspokes, and it is contemplated that the use of dual tubes and nipplesmay be utilized on the various alternative embodiments of the presentinvention discussed above.

While the wheel with flexible spokes of the present invention as hereinshown and disclosed in detail is fully capable of obtaining the objectsand providing the advantages herein before stated, it is to beunderstood that it is merely illustrative of preferred and alternativeembodiments of the invention and that no limitations are intended to thedetails of construction or design herein shown other than as describedin the appended claims.

I claim:
 1. A flexible aerodynamic spoke comprising: a non-rigid fibermaterial having a first end and a second end; a jacket with across-section covering said non-rigid fiber material; a first tubeformed with a tapered bore attached to said first end of said non-rigidfiber material; a second tube formed with a tapered bore attached tosaid second end of said non-rigid fiber material; a first nipple,wherein said first tube is secured to said first nipple; and a secondnipple, wherein said second tube is secured to said second nipple. 2.The flexible aerodynamic spoke of claim 1, wherein said cross-section ofsaid jacket is a teardrop shape.
 3. The flexible aerodynamic spoke ofclaim 1, wherein said cross-section of said jacket is an oblong shape.4. The flexible aerodynamic spoke of claim 1, wherein said cross-sectionof said jacket is an aero-dynamic shape having a pointed leading edgeand a pointed trailing edge.
 5. The flexible aerodynamic spoke of claim1, wherein said non-rigid fiber material first end is formed as a firstend wedge to be received by said tapered bore of said first tube andsaid non-rigid fiber material second end is formed as a second end wedgeto be received by said tapered bore of said second tube.
 6. A flexibleaerodynamic spoke comprising: a flexible shaft having a first end formedas a first end wedge and a second end formed as a second end wedge; anaerodynamic jacket with a cross-section covering said flexible shaft; afirst tube formed with a tapered bore, wherein said first end wedge isreceived by said tapered bore of said first tube; a second tube formedwith a tapered bore, wherein said second end wedge is received by saidtapered bore of said second tube; a first nipple, wherein said firsttube is secured to said first nipple; and a second nipple, wherein saidsecond tube is secured to said second nipple.
 7. The flexibleaerodynamic spoke of claim 6, wherein said flexible shaft comprisesnon-rigid fibers covered by a flexible shaft jacket.
 8. The flexibleaerodynamic spoke of claim 7, wherein said non-rigid fibers comprises aplurality of filaments.
 9. The flexible aerodynamic spokes of claim 7,wherein said non-rigid fibers comprises forty-four (44) bundles ofnine-hundred ninety-six filaments in each said bundle.
 10. The flexibleaerodynamic spokes of claim 7, wherein said non-rigid fibers comprisesPBO fibers.
 11. The flexible aerodynamic spoke of claim 7, wherein saidcross-section of said aerodynamic jacket is a teardrop shape.
 12. Theflexible aerodynamic spoke of claim 7, wherein said cross-section ofsaid aerodynamic jacket is an oblong shape.
 13. The flexible aerodynamicspoke of claim 7, wherein said cross-section of said aerodynamic jacketis an aero-dynamic shape having a pointed leading edge and a pointedtrailing edge.
 14. The flexible aerodynamic spoke of claim 7, whereinsaid first end wedge and said second end wedge each consists of saidnon-rigid fiber material and an epoxy.
 15. A flexible aerodynamic spokecomprising: a first tube formed with a tapered bore; a first nippleconfigured to attach said first tube to a rim; a second tube formed witha tapered bore; a second nipple configured to attach said second tube toa wheel hub; a flexible shaft comprising a non-rigid fiber materialhaving a first end formed as a first end wedge to be received by saidtapered bore of said first tube and a second end formed as a second endwedge to be received by said tapered bore of said second tube; and anaerodynamic jacket with a cross-section covering said flexible shaft.16. The flexible aerodynamic spoke of claim 15, wherein said first endwedge and said second end wedge each consists of said non-rigid fibermaterial and an epoxy.
 17. The flexible aerodynamic spoke of claim 15,wherein said cross-section of said aerodynamic jacket is a teardropshape.
 18. The flexible aerodynamic spoke of claim 15, wherein saidcross-section of said aerodynamic jacket is an oblong shape.
 19. Theflexible aerodynamic spoke of claim 15, wherein said cross-section ofsaid aerodynamic jacket is an aero-dynamic shape having a pointedleading edge and a pointed trailing edge.
 20. The flexible aerodynamicspokes of claim 15, wherein said non-rigid fibers comprises PBO fibers.